Fill block

ABSTRACT

A fill block is provided for a CNG fuel system for a transit bus or similar vehicle. The fill block includes a integral one piece body having first and second ends defining a length therebetween. The body has a main bore defined therein. A ball valve is received in the body and has a handle extending from the body. The ball valve is movable between open and closed positions, wherein the main bore is opened and closed, respectively. A fueling port is defined in the body and communicated with the main bore. A defueling port is defined in the body and communicated with the main bore. A fueling receptacle is connected to the fueling port. A defueling receptacle is connected to the defueling port. A defueling valve is provided for selectively communicating the defueling port with the main bore or isolating the defueling port from the main bore.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to fill blocks, sometimesreferred to as manifolds, for providing connections between a compressednatural gas fuel system for a bus or other vehicle and a filling stationwhere the vehicle is filled with fuel.

2. Description of the Prior Art

Typical prior art CNG fuel systems have utilized a multi-part fill blockwherein many of the components such as the primary shutoff valve areseparate components which are threadedly connected to the main fillblock body. The fill block did not provide any means for defueling ofthe vehicle. All of the threaded connections on the fill block were NPTthreads, that is tapered pipe threads.

Although these prior art fill block assemblies do satisfactorily performtheir intended purpose, there is much room in the art for improvement offill block designs to simplify their construction and to improve theirperformance.

SUMMARY OF THE INVENTION

The present invention provides an improved fill block for a CNG fuelsystem for a vehicle. The fill block includes an integral one piece bodyhaving first and second ends defining a length therebetween, and havinga main bore defined in the body. A ball valve is received in the bodyand has a handle extending from the body. The ball valve is moveablebetween open and closed positions wherein the main bore is opened andclosed, respectively. A fueling port is defined in the body and iscommunicated with the main bore. A defueling port is defined in the bodyand communicated with the main bore. A fueling receptacle is connectedto the fueling port. A defueling receptacle is connected to thedefueling port. A defueling valve is located in the body for selectivelycommunicating the defueling port with the main bore and for isolatingthe defueling port from the main bore as desired.

The body also includes various vent ports and sensor gauge portscommunicated with the main bore. Preferably all of the threadedconnections to the body are SAE threads which provide a much more secureand reusable threaded connection than do the NPT threads of the priorart.

It is therefore, an object of the present invention to provide animproved fill block for use with a CNG fuel system for a vehicle.

Another object of the present invention is the provision of a fill blockfor a CNG fuel system wherein the fill block includes an integrallymounted shutoff ball valve.

Another object of the present invention is the provision of a fill blockfor a CNG fuel system which includes a means for defueling the system.

Still another object of the present invention is the provision of a fillblock using a SAE threads for all threaded connections.

Another object of the present invention is to provide a fuel blockhaving pressure gauge connections on either side so the block is“reversible.”

Other and further objects, features and advantages of the presentinvention will be readily apparent to those skilled in the art upon thereading of the following disclosure when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective schematic view of a transit bus having a roofmounted CNG fuel supply system.

FIG. 2 is a plan view of the support framework for supporting thecylindrical tanks on the roof of the bus.

FIG. 3 is a side elevation view of the support framework of FIG. 2.

FIG. 4 is an end elevation view taken along line 4—4 of FIG. 2 andshowing four tanks in place, and also showing the tank cover which issupported upon the framework.

FIG. 5 is an enlarged end elevation view showing the mounting of two ofthe tanks to a first longitudinal frame wall of the support frame.

FIG. 6 is a schematic plan view showing the CNG manifold line and theinlet and outlet lines connecting six tanks to the manifold line.

FIG. 7 As a view similar to FIG. 6 and showing eight tanks connected tothe manifold line.

FIG. 8 is a perspective view showing the inlet and outlet linesassociated with tanks 1 and 2.

FIG. 9 is a perspective view showing the inlet and outlet linesconnecting tank 6 to the manifold line.

FIG. 10 is a plan view of the inlet line for tank 24. The inlet line fortank is identical.

FIG. 11 is a plan view of the outlet line for tank 24.

FIG. 12 is a plan view of the inlet line for tank 26. The inlet line fortank 28 is identical.

FIG. 13 is a plan view of the outlet line for tank 26. The outlet linefor tank 28 is identical.

FIG. 14 is a plan view of the outlet line for tank 30.

FIG. 15 is a perspective view of the first portion of the inlet line oftank 34.

FIG. 16 is a plan view of the second portion of the inlet line of tank34. The second portion of the inlet line of tank 32 is identical.

FIG. 17 is a perspective view of the outlet line for tank 34.

FIG. 18 is a perspective view of the pressure relief system tubing.

FIG. 19 is a front elevation view of the fill block.

FIG. 20 is a left side elevation view of the fill block.

FIG. 21 is a right side elevation view of the fill block.

FIG. 22 is a rear elevation view of the fill block.

FIG. 23 is a left side elevation view similar to that of FIG. 20, buthaving part of the upper portion cut away to show the internal detailsof construction of the ball valve.

FIG. 24 is a view similar to FIG. 19 having a portion thereof cut awayto show the details of construction of the defueling valve.

FIG. 25 is a bottom end view of the fill block.

FIG. 26 is a perspective view of the fill block.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 1, a bus is shown and generally designated by thenumeral 10. The bus 10 has a front 12, a rear 14, and a roof 16. The bushas a width 18 and a length 20.

A CNG fuel system for the bus is generally designated by the numeral 22.

The fuel system 22 includes a plurality of rearward tank cylindersmounted on the top of the bus and extending parallel to the length 20 ofthe bus. The plurality of rearward tank cylinders includes firstcylinder 24, second cylinder 26, third cylinder 28 and fourth cylinder30. The system 22 also includes a plurality of forward tank cylindersincluding fifth tank cylinder 32 and sixth tank cylinder 34.

The tanks are NGV Type 4 fuel containers certified to U.S. DOT FMVSS 304and the 1998 version of ANSI/IAS NGV-2, the details of which can beobtained from the American National Standards Institute in New York,N.Y. Such tanks can be obtained from Lincoln Composites of 6801Cornhusker Highway, Lincoln, Nebr. 68507. Type 4 tanks utilize a plasticliner with a carbon fiber overwrap. The tanks are supported by a pair ofsaddles and strap assemblies which typically support the tanks atapproximately ¼ the distance from either end of the tank. Such tanks arereferred to throughout this application as Type 4 tanks.

A fill box 36 is mounted on the rear of the bus adjacent the curb side.

The fill box 36 contains a fill block, filters, pressure regulators andthe like, which are a typical part of a CNG fuel system. The fill box 36provides a location where CNG can be provided from a source to fill thesystem 22.

The rear 14 of the bus is partially cut away in FIG. 1 to schematicallyillustrate the location of the engine 38. A fuel line (not shown) runsfrom the fill box 36 to the engine 38.

A manifold line 40 includes a first lengthwise portion 42 which runsalong the length of the bus to a location between the front and reartank cylinders, and then the manifold line 40 includes a transverseportion 44 which runs at least partially across the width of the busbetween the forward tank cylinders 32, 34 and the rearward tankcylinders 24-30. As is further described below with regard to FIG. 5,the transverse portion 44 of manifold line 40 is connected to each ofthe tanks 24-34.

The Support Frame

FIG. 1 is a schematic illustration and generally shows the location ofthe tanks 24-34. The tanks 24-34 are actually supported upon the roof 16of the bus by means of a support frame 46 which is shown in FIGS. 2 and3. The support frame 46 is mounted on the roof 16 of bus 10.

The support frame 46 includes a first longitudinal frame wall 48 havinga forward portion 50 and a rearward portion 52. The support frame 46further includes a second longitudinal frame wall 54 including a forwardportion 56 and a rearward portion 58.

The first longitudinal frame wall 48 has a height 86 extendingvertically from the roof of the bus.

Support frame 46 further includes a removable central support 60 havinga forward portion 62 and a rearward portion 64.

Support frame 46 includes a center transverse wall 66 to which theforward and rearward portions of first and second walls 48 and 54 andcenter support 60 are attached to join those forward and rearwardportions.

Support frame 46 further includes a forward transverse wall 68 to whichthe forward ends of each of the longitudinal walls are attached, and arearward transverse wall 70 to which the rearward ends of each of thelongitudinal walls are attached. The transverse outer ends of the threetransverse walls are connected by hinge support tubes 72.

In the side elevation view of FIG. 3, to the left of center transversewall 66, the details of the rear portion 52 of the first longitudinalframe wall 48 are shown. To the right of center transverse wall 66 inFIG. 3 the first longitudinal frame wall 48 is cut away to show thedetails of construction of the removable central support 60. As is thereapparent, first and second longitudinal frame walls 48 and 54 areconstructed as trusses having upper and lower beams 74 and 76 separatedby a plurality of vertical columns 78 and cross braces 80.

The center support wall 60, on the other hand, is not supporting anysubstantial weight, because its sole purpose is to support the outercover doors 82 and 84 as seen in FIG. 4. The cover doors 82 and 84 arehingedly connected to the hinge rails 72 and their interior edges reston top of the central support 60 as seen in FIG. 4. In FIG. 4, the leftside door 82 is pivoted open, and the right side door 84 is shownclosed.

The first and second longitudinal frame walls 48 and 54 provide thestructural support for the tanks 24-34 as is further described belowwith regard to FIGS. 4 and 5.

With reference to the plan view of FIG. 2, it will be understood thatthe first tank 24 will lie between rear section 52 of wall 48 and theadjacent outer hinge tube 72, and between the center transverse wall 66and rearward transverse wall 70. The second tank 26 will lie parallelthereto on the opposite side of the rear section 52 of firstlongitudinal wall 48. The third tank will lie parallel thereto betweenthe rear section 64 of center support 60 and the rear section 58 ofsecond longitudinal wall 54. The fourth tank will lie on the oppositeside of rear section 58 of second wall 54.

The fifth tank will lie longitudinally between center transverse wall 66and forward transverse wall 68, and will lie between the forward section50 of first wall 48 and the adjacent outer hinge rail 72. The sixth tankwill lie parallel thereto between the forward section 56 of secondlongitudinal wall 54 and the adjacent outer hinge rail 72.

As is best illustrated in FIGS. 4 and 5, the first and second tanks 24and 26 are supported in a cantilever mode from the rear section 52 offirst longitudinal frame wall 48. This is accomplished as follows.

Referring to FIG. 3, it is seen that the rearward section 52 of firstlongitudinal frame wall 48 includes four of the vertical columns 78which are arranged in two back-to-back pairs of column 78. Each column78 carries two mounting holes 88. As further illustrated below withregard to FIGS. 4 and 5, each set of four mounting holes 88 is utilizedto mount two back-to-back saddles such as 90 and 92.

Each saddle member, such as saddle member 92 includes a verticallyoriented planar base surface 94 and an arcuate recessed surface 96facing laterally outward, i.e. sideways, from the first frame wall 48.

A plurality of bolts 95 extend laterally through the saddles 90 andthrough the bolt holes 88 of vertical column members 78 of wall 48, toattach the saddle members 90 and 92 to the wall 48.

The tank 26 is received in the arcuate recess 96 and held therein by astrap assembly 98 comprised of a shorter strap member 100 and a longerstrap member 102. The shorter strap member 100 is pivotally attached tosaddle 92 at pivot 104. The longer strap member 102 is pivotallyattached to saddle 92 at lower pivot 106. The shorter and longer strapmembers 100 and 102 have free ends 108 and 110, respectively, which arejoined together by a bolt 112 to tighten the strap assembly 98 about thetank 26 to hold it in place within the recess 96 of saddle 92. Bolt 112provides a releasable connection between strap members 100 and 102.

Referring again to FIG. 3, it is seen that there is one pair of verticalcolumn members 78 near the rear end or left hand side of FIG. 3 and asecond pair of vertical column members 78 to the right thereof nearerthe center beam 66. For each tank there will be two of the saddlemembers such as 90, one of which is mounted to each of these twolocations which correspond to approximately the quarter points from theends of the tank.

It is noted that the saddle member 92 and associated strap assembly 98are themselves a part of the prior art and are provided by themanufacturer as part of a Type 4 tank. In the prior art, however, thesaddle members 92 have always been mounted in a horizontal orientationwith the recess 96 facing upward and thus supporting the tanks in acompressive mode, not a cantilever mode. The re-orientation of thesaddle members vertically and thus the mounting of the tanks in acantilever mode from vertical wall 48 is a novel part of the presentinvention.

With the vertical orientation of the saddles utilized in the presentinvention for the two inner tanks 26 and 28, the longer strap portion102 should be connected to the lower end of the saddle 92 as at 106 sothat the longer strap portion underlies the tank and so that the shorterstrap portion 100 overlies the tank. For the outer tanks 24 and 30 thisarrangement is reversed and the longer strap is placed on top.

Although in FIG. 5, two tanks 24 and 26 are shown hung in a cantilevermode off opposite sides of the first longitudinal frame wall 48, asingle tank can be hung in the same manner in a cantilever mode offeither side of the wall. For example, the fifth tank is hung in a mannersimilar to tank 24 off the right hand side of the forward section 50 ofthe first frame wall 48.

When there are four tanks oriented side-by-side, such as in the group offour forward tanks 24, 26, 28 and 30 as seen in FIG. 4, the first andfourth tanks 24 and 30 may be referred to outer tanks, and the secondand third tanks 26 and 28 may be referred to as inner tanks. The secondand third tanks 26 and 28 are separated by, but are not attached, to thecenter support 60.

As previously noted, the center support 60 is removable and its basicpurpose is to provide a support for the inner edges of the cover doors82 and 84 as seen in FIG. 4. The center support 60 is constructed in aremovable fashion so as to aid access to the inner cylinders 26 and 28and to aid the removal of either of the inner cylinders 26 or 28 withoutremoval of any of the other tank cylinders.

As previously noted, when using the prior art mounting arrangement, suchas that used by New Flyer wherein the saddle members are mountedhorizontally below the tanks, the inner tanks cannot be removed, becausethe strap assemblies cannot pivot open wide enough to release them.Thus, with the prior art arrangement having horizontally mountedsaddles, it is typically necessary to first remove the adjacent outertanks, such as 24 or 30, before the selected inner tanks, such as 26 or28, may be removed.

The removable construction of the center support 60 is best illustratedon the right hand side of FIG. 3. There it is seen that the centersupport 60 is made up of a plurality of removable support posts 114,each having a bolt plate 116 on its lower end and having a horizontallyoriented box tube 118 at its upper end which has open ends, such as 120.The edges of cover doors 82 and 84 rest on the box tubes 118. The boltplates 116 are bolted to a lower beam 122 which lies near the roof ofthe bus. Thus, to remove the center support 60 the bolt plates 116 areunbolted from the beam 122, and the posts 114 are removed.

Typically, when it is desired to remove one of the tank cylinders, andparticularly one of the inner tank cylinders 26 or 28 that isaccomplished as follows.

First, the support posts 114 of center support 60 are unbolted from beam122 and removed.

Then, a lifting device such as a set of straps and cables are placedaround the tank at one or more locations (not shown).

Then, the strap assemblies 98 of the selected tank are removed byloosening the bolts 112 thereof. Then, the shorter strap members 98 arepivoted up and away from the tank, and the lower strap members 102 falldownward to a sufficient degree that the tank can be lifted out of thesupport frame 46 without removing the adjacent outer tank 24.

The Inlet and Outlet Tubing

Turning now to FIG. 6, a schematic plan illustration is there shown ofthe manner in which the transverse portion 44 of manifold line 40 isconnected to the tanks 24-34.

The transverse manifold line 44 is anchored to the support frame 46 byclamps (not shown) which are typically spaced at approximately 24 inchesapart. It is noted that codes such as NFPA 52 require the anchoring ofthe manifold line 40 at eighteen to twenty-four inch spacings.

The transverse manifold line portion 44 is a single manifold line 44lying between the forward and rearward groups of tanks with all of thetanks of both the forward and rearward groups being connected to thesingle transverse manifold line 44. This is contrasted to the prior artarrangements like those used by Orion and New Flyer wherein they use twoparallel transverse manifold lines, one for their forward set of tanksand the other for the rearward set of tanks.

Beginning with the first tank 22, there is a T 124 located in transversemanifold line 44. Although for purposes of ease of illustration, thesecomponents have been shown in a simplified plan view in FIG. 6, it willbe understood that the transverse manifold line 44 actually lies at anelevation below that of tank 24. The center leg 126 of T 124 is actuallyoriented in a vertically upward direction. A short tubing nipple 128 isconnected to leg 126, and a solenoid valve 130 is connected thereto. Thesolenoid valve 130 has a 900 elbow 132 attached thereto.

The solenoid 130 is preferably a Parker/Skinner Model MB1480-P01 highpressure solenoid valve having a {fraction (1/32)} inch orifice.

The tank 24 includes a manual shutoff valve 134 mounted in its endadjacent the transverse manifold line 44. The manual shutoff valve 134has two laterally open ports 136 and 138 defined therein on oppositesides thereof facing toward the left and right sides of the bus.

An inlet line 140 connects the solenoid 130 to the first port 136 ofmanual shutoff valve 134 and thus to the tank 24. The details ofconstruction of inlet line 140 are shown in FIG. 10. Inlet line 140 isconstructed of ½ inch nominal diameter by 0.065 inches wall thicknessSS316 seamless bright annealed tubing. It has first and second legs 142and 144 joined by a continuous 180° bend 146 which has a 1½ inch radius148 to the center line of the tubing. The leg 142 has a length 150 of 7¼inches and leg 144 has a length 152 of 6⅝ inches. All the dimensions ofthis tubing component and the others described hereafter are specifiedto tolerances of ±⅛ inch.

The continuous 180° bend 146 in association with the legs 142 and 144defines a bendable expansion portion 146 which accommodates longitudinalexpansion of the tank cylinder 24 relative to the transverse manifoldline 44.

As will be appreciated by those skilled in the art, compressed naturalgas is conventionally stored at very low temperatures, and thus when thetanks are first filled, the gas contained therein will be at arelatively low temperature. Subsequently, the CNG will warm up, thussubstantially increasing its pressure, which creates the need for thespecially constructed carbon fiber wrap high pressure tanks such as theType 4 tank. These tanks are constructed to accommodate the changes intemperature and there are substantial dimensional changes of the tankdue to thermal expansion. A typical Type 4 tank having a nominalcapacity of 3,000 SCF/tank has a nominal length of approximately 120inches and a nominal diameter of approximately 15.9 inches. The lengthof the tank can change by as much as three quarters of an inch due tothermal expansion and contraction. This expansion primarily occurs inthe inner liner and the growth and length of the tank occurs at theends, and may occur at either end. Thus, the tubing connecting the tankto the fixed transverse manifold line 44 must be designed to accommodateas much as three quarters of an inch of movement of the manual shutoffvalve 134 which is attached to the end of the tank 24.

Turning now to the other tubing connected to tank 24, there is a secondT 154, nipple 156, a check valve 158, a nipple 160 and another T 162which leads to inlet tubing 164.

The check valve 158 is preferably a Hoke ½ inch check valve.

The details of construction of inlet tube 164 are best shown in FIG. 11.Inlet tube 164 includes a longer first leg 166, a shorter second leg168, and a continuous 180° bend 170 connecting the two legs. Leg 166 hasa length 172 of 16{fraction (5/16)} inches. Leg 168 has a length 174 of4{fraction (1/16)} inches. The continuous bend 170 has a 1½ inch radiusto its center line. The tubing 164 is ½ inch nominal diameter by 0.065inches wall thickness SS316 seamless bright annealed tubing.

It is noted that in the arrangement illustrated in FIG. 6, the checkvalve 158 serves to allow flow from transverse manifold line 44 to boththe first and second tanks 24 and 26.

An inlet tube 176 associated with tank 26 is connected to one of thearms 178 of T 162. The tank 26 also has a manual shutoff valve 180 withports 182 and 184. Inlet tube 176 is connected to port 182. The detailsof construction of inlet tube 176 are best shown in FIG. 12. Inlet tube176 includes a short leg 186 having a length 188 of 7{fraction (11/16)}inches, a long leg 190 having a length 192 of 14¾ inches, and acontinuous 180° bend 194 having a 1½ inch radius to its center line.Again, the tube is constructed from ½ inch nominal diameter by 0.065inches wall thickness SS316 seamless bright annealed tubing. Thecontinuous bend 194 provides a bendable inlet expansion portion 194 foraccommodating the longitudinal movement of tank 26 due to thermalexpansion.

Another T 196 is located in the transverse manifold conduit 44 and isconnected by nipple 198 to a second solenoid valve 200 which controlsflow of fluid out of tank 26. The solenoid valve 200 is connected to anelbow 202 which is in turn connected to an outlet line 204 whichconnects to the second port 184 on tank 26.

The details of construction of outlet line 204 are best seen in FIG. 13.It includes a longer leg 206 having a length 208 of 6¾ inches, a shorterleg 210 having a length 212 of 4 inches, and a continuous 180° bendportion 214 having a 1½ inch radius to its center line. The tube 204 isagain constructed of ½ inch nominal diameter by 0.065 wall thicknessSS316 seamless bright annealed tubing.

It is noted that in the embodiment illustrated in FIG. 6, the first andsecond tanks 24 and 26 share a common check valve 158 which controlsflow of gas to their inlet lines 164 and 176. They each have separatelycontrolled outlet or solenoid valves 130 and 200 which control flow ofCNG out of the tanks back to the transverse manifold line 44 to supplyfuel to the engine of the bus. It is noted that in an alternativeembodiment of the invention, the function of the inlet and outlet linescan be reversed. The single check valve 158 can be replaced with asingle solenoid valve controlling flow out of both of the tanks 24 and26, and the two solenoid valves 130 and 200 can be replaced with checkvalves separately allowing flow of gas into the tanks when the tanks arebeing filled. This alternative arrangement could be desirable if moreflow capacity was needed to rapidly fill the tanks 24 and 26.

It is noted that with either arrangement, the tank may be shut off byits manual shutoff valve, and the solenoid 130 or 200, regardless ofwhere it is placed, may be removed without the need to empty and purgeits associated tank. This is contrasted to prior art arrangements likethat of New Flyer, wherein the solenoid valves are directly mounted inthe end of the tanks, and upon failure of a solenoid valve, it isnecessary to completely empty and purge two tanks to allow the solenoidvalve to be removed therefrom and replaced. Two tanks must be purgedbecause the tanks are plumbed together in pairs and there is no way toisolate them.

Turning now to the next pair of tanks 28 and 30, it will be seen thatmany of the tubing components associated therewith are identical tothose associated with the first pair of tanks 24 and 26. In this furtherdescription it is noted that the various minor components such asnipples are not mentioned, although their presence is apparent from thedrawings.

A T 216 is connected to a solenoid valve 218 which is connected to anoutlet line 220 which is substantially identical in construction to theoutlet line 204 previously described for tank 26.

A T 222 is connected to a check valve 224 which is connected to anotherT 226. An inlet line 228 from T 226 to tank 28 is substantiallyidentical in construction to the inlet line 176 of tank 26.

The other side of the T 226 is connected to an inlet line 230 which isconnected to tank 30. The inlet line 230 is substantially identical inconstruction to the inlet line 164 of tank 24.

An elbow 232 is connected to the end of transverse manifold line 44. Asolenoid valve 234 is connected to the elbow 232 and then to an outletline 236 connected to fourth tank 30.

The details of construction of outlet line 236 are best seen in FIG. 14.Outlet line 236 includes a longer leg 238 having a length 240 of 8¼inches, and a shorter leg 242 having a length 244 of 7⅛ inches. The twolegs are joined by a continuous 180° bend portion 246 having a 1½ inchradius to its center line. The outlet tube 236 is constructed from ½inch nominal diameter by 0.065 inches wall thickness SS316 seamlessbright annealed tubing.

FIG. 8 is a perspective view of the manifold line 44 and the inlet andoutlet tubing at tanks 24 and 32. This view is taken from in front ofthe tanks looking rearward. In FIG. 8, pressure relief devices 260 and262 and vent lines 264 and 266 associated with tanks 24 and 26,respectively, are also shown.

The following alternative description is also applicable to the tubingarrangement associated with first and second tanks 24 and 26. The tanks24 and 26 can be described as extending parallel to the length of thebus both on the same side of the transverse manifold line 44.

In the following description the inlet lines are referred to as firstlines and the outlet lines are referred to as second lines. Thisterminology allows for the possibility as noted above, that the solenoidvalves and check valves may be swapped so that the first line becomesthe outlet line and the second line becomes the inlet line.

The T 154, nipple 156, check valve 158, nipple 160 and T 162 provide acommon first line portion connected to the manifold line 44 and havingthe check valve 158 disposed therein which allows flow toward the firstand second cylinders 24 and 26. The T 162 is connected to or may beconsidered part of the common first line portion. Then, first and secondhydraulically parallel separate first line portions 164 and 176separately connect the T 162 to the first and second cylinder tanks 24and 26, respectively, each of the separate first line portions 164 and176 including a flexible expansion loop having a continuous 180° bend.

Each of the separate first line portions 164 and 176 may be described asincluding two legs each lying generally parallel to the width of the busand the continuous 180° bend connects the two legs.

Similarly, the system may be described as including two second lines 140and 204 connecting the manifold line 44 to the first and second tankcylinders 24 and 26, respectively, each second line 140 and 204including a flexible expansion loop having a continuous 180° bend. Inthe embodiment illustrated, the first line is an inlet line and the twosecond lines are outlet lines, but as previously noted, the solenoidvalves and check valves may be interchanged so that there is a singlecommon outlet line and two separate inlet lines.

To this point, we have described a plurality of inlet lines 164, 176,228 and 230 and a plurality of outlet lines 140, 204, 220 and 236.Dimensions and details of construction have been given to provideexamples of bendable expansion portions having sufficient flexibilityand strength to accommodate the expansion of the tanks.

Each of these inlet and outlet lines are preferably machine bent tubingpre-fabricated to specified tolerances so that pre-fabricatedreplacement parts may be substituted for original parts to repair thetubing system illustrated in FIG. 6.

This pre-fabricated construction to specified tolerances leads to anumber of advantages.

First, it is noted that the system is designed for use with a largefleet of perhaps several hundred city transit buses utilizingsubstantially identical CNG fuel supply systems.

The system is preferably designed so that even within the set of tubingfor one bus there will be numerous substantially identical parts such asthe identical inlet tubes 176 and 128, and the other identical inlettubes 164 and 230, and similarly there are identical outlet tubes, suchas 204 and 220. This use of identical parts within a system, and thenthe use of identical prefabricated components for the CNG fuel supplysystem of each bus of a fleet of buses, allows the components to bepre-fabricated and interchanged between systems. It also allows aninventory of a minimum number of components to be kept for subsequentrepair and replacement of the fuel systems of the buses within thefleet.

As will be understood by those skilled in the art, the machine benttubing is manufactured on a computer numerically controlled bendingmachine. Such machine bent tubing can be obtained for example from AtlasHydraulic of Brantford, Ontario, Canada.

Continuing with the description of FIG. 6, it is noted that in FIG. 6only two forward tanks are utilized. In this arrangement, the tubingconnections to the two forward tanks will be different from those forthe four rearward tanks. It is noted, however, that the systemillustrated in FIG. 6 is constructed in order to be easily converted tothe system shown in FIG. 7, wherein there are four forward tanksutilizing inlet and outlet tubing substantially identical to that of thefour rearward tanks, thus again reducing the number of different tubingparts.

In FIG. 6, the inlet and outlet tubing for the two forward tanks 32 and34 is illustrated in schematic fashion. FIG. 9 shows a perspective viewof the tubing connected to tank 34. FIG. 9 is a view from behind tank 34facing forward. The physical arrangements of tubing for tanks 32 and 34are similar to each other.

The transverse manifold line 44 includes a T 248 which is connected to afirst inlet line portion 250 which is connected to a check valve 252which is in turn connected to a second inlet line portion 254 which isconnected to a port 256 on the manual shutoff valve 258. A solenoid 268is connected to second port 270. An outlet line 272 connects solenoid268 to a T 274.

The details of construction of first tubing section 250 are best shownin FIG. 15. First tubing section 250 includes a first portion 276parallel to the length of the bus of length 3 inches, a 90° bend 278, ariser portion 280 of 8¼ inch length, another 90° bend 282, and a thirdportion 284 of 4¼ inch length parallel to the width of the bus.

The details of construction of second tubing section 254 are shown inFIG. 16. The second tubing section 254 includes a leg 286 of length8{fraction (1/10)} inches which can be considered on extension of thirdportion 284. Second tubing section 286 also includes a 180° bend 288 anda shorter leg 290 of length 3⅝ inches which connects to port 256.

The details of outlet line 272 are best shown in FIG. 17. Outlet line272 includes a first portion 292 of length 5¾ inches parallel to thelength of the bus, a 90° bend 294, a second portion 296 of length 11⅞inches parallel to the width of the bus, a second 90° bend 298, and ariser portion 300 of length 4⅝ inches connected to solenoid 268 and thusto outlet 270.

It is noted that inlet line 250 and outlet line 272 are connected to T's248 and 274 of manifold line 44 at locations offset to the right handside of tank 34 in FIG. 6, and the widthwise extensions of both linesextend to the left back toward the tank to define a shape in plan viewas in FIG. 6 which can be described as a double dog-leg expansion loop.

The tubing connections to tank 32 as seen in FIG. 6 are essentially amirror image of those to tank 34 seen in FIGS. 6 and 9, thus forming asecond double dog-leg expansion loop extending in the opposite directionwidthwise from the first double dog-leg expansion loop.

A T 302 is connected to a first inlet line portion 304, which isconnected to check valve 306, which is connected to a second inlet lineportion 308, which connects to port 310 on shut off valve 312. Asolenoid 316 is connected to second port 314 of valve 312. An outletline 318 connects solenoid 316 to T 320 in manifold line 44.

All the tubing components described above for the inlet and outlet linesare ½ inch nominal diameter by 0.065 inches wall thickness SS316seamless bright annealed tubing. All 90° bends and all 180° bends are 1½inch radius to the centerline of the tubing.

Advantages of Fleet Usage

When utilizing such a fleet of buses utilizing substantially identicalCNG fuel supply systems in accordance with the present invention, eachbus is provided with a plurality of roof mounted Type 4 tanks.

A plurality of pre-fabricated tubing pieces are machine bent tospecified tolerances for the fuel system of each of the buses of thefleet so that the tubing pieces are interchangeable between buses. Allof the dimensions of the examples which have been described above arespecified to tolerances of ±⅛ inch.

Each bus is provided with a substantially identical roof mountedmanifold line 44 for supplying fuel to the engine of the bus.

Each of the tanks of each bus is connected to its associated manifoldline with both an inlet tubing piece and an outlet tubing piece selectedfrom the prefabricated tubing pieces.

Then the fleet of buses may be maintained by utilizing substituteprefabricated tubing pieces kept in a maintenance inventory for repairof the fleet of buses. A minimal number of pieces will need to bemaintained in the maintenance inventory, due to the fact that each ofthe pieces is machine bent to specified tolerances and the system isdesigned so that a minimum number of different shaped pieces arerequired and so that each bus utilizes these same identical pieces.

The Relief System

FIG. 18 is a perspective view of the pressure and thermal relief system,associated with tanks 24 and 26. FIG. 18 is a view from the rear end oftanks 24 and 26 looking toward the front of the bus. For purposes ofillustration, the supporting structure supporting the tanks 24 and 26,and other tubing connected to those tanks is not shown.

As has already been described and illustrated in FIG. 8, the forwardends of each of the tanks 24 and 26, which are the right hand ends inFIG. 18, have shutoff valves 134 and 180, respectively, attachedthereto. Those shutoff valves have relief devices 260 and 262,respectively, attached directly to the shutoff valves, and they havevent lines 264 and 266 leading upward from the relief devices 260 and262.

Additionally, there are two other pressure relief devices which areassociated with the pair of tanks 24 and 26. These relief devices andtheir associated tubing are shown in FIG. 18.

The pressure relief devices 260 and 262 may be described as first andsecond relief devices attached directly to the shutoff valves 134 and180 of first and second tanks 24 and 26, respectively.

As shown in FIG. 18, the tanks 24 and 26 have outlet couplings 322 and324, respectively, connected to their second ends.

Outlet coupling 322 is connected to an elbow 324 which is connected to afirst separate relief outlet line 328. Outlet coupling 324 is connectedto an elbow 330 which is connected to a second separate relief outletline 332.

The two separate relief outlet lines 328 and 322 connect to a common T334 which is connected to a common relief line 336 which is locatedgenerally parallel to and lying between the first and second tanks 24and 26.

It is noted that each of the first and second separate outlet relieflines 328 and 332 includes a continuous 180° bend portion 338 and 340,respectively, to allow flexibility in the outlet relief line toaccommodate thermal expansion of the second end of the Type 4 tanks 24and 26 relative to the outlet relief lines in a manner like thatpreviously described for the tubing at the other end of the tanks.

Third and fourth relief devices 342 and 344 are connected to the common,relief line 336.

The third relief device 342 is connected to a T 346 and the outlet ofrelief device 342 is connected to a vent line 348.

At the end of the common relief line 336, there is an elbow 350 whichis, connected to the fourth relief device 344. A vent line 352 isconnected to the outlet of the fourth relief device 344.

Thus, it is seen that each of the four relief devices 260, 262, 342, and344 can serve to relieve pressure in both of the tanks 24 and 26 ifeither an over pressure or an over temperature condition is sensed atany one of the relief devices. Because the two tanks 24 and 26 areconnected together at their second ends by the outlet relief tubing 328,332 they will both be relieved if either of the pressure relief devices260 or 262 at their first ends opens or if either of the relief devices342 or 344 in the common relief line 336 opens.

All of the relief devices utilize SAE threads to connect to theirassociated tubing components.

As will be understood by those skilled in the art, the primary danger toa fuel system such as that described herein is due to fire, rather thanan over pressure condition. Each of the relief devices is located atpositions spaced along the area covered by the pair of tanks 24 and 26,so if a fire were to occur in any area near the tanks, one of the fourrelief devices would soon be exposed to the excessive temperature whichwould cause that device to open, thus relieving pressure from both ofthe tanks.

As seen in FIG. 18, the third relief device 342 is located very near thesecond ends of the tanks 24 and 26. The fourth relief device 344 islocated a distance 354 which is preferably approximately one-third thelength of the tanks 24 and 26 from their first ends toward their secondends.

The relief devices are preferably a Model 91816/RV99-300, specified for219° F. and 3600 psig relief, manufactured by Circle Seal/Hoke of CoronaCalif. This unit utilizes a eutectic operational device that will eitherflow due to excessive pressure or melt due to excessive temperature inorder to open the relief member.

The Fill Block

FIG. 1 shows the fill box 26 which as previously noted contains a fillblock, filters, pressure regulators and the like. The fill box 26provides a location where CNG can be provided from a source, such as afilling station, to fill the system 22 of the bus 10.

An improved fill block is shown in FIGS. 19-26 and is generallydesignated by the numeral 400. The fill block 400 includes a integralone piece body 402 which is machined from a solid block of aluminum. Thebody 402 has first and second ends 404 and 406 which may also bereferred to as upper and lower ends 404 and 406.

The body 402 has first, second, third and fourth sides 408, 410, 412,and 414 which may also be described as front side 408, right side 410,rear side 412 and left side 414.

The body 402 has a length between its ends 404 and 406 of approximately11 inches and its sides are approximately 3 inches wide.

The body 402 has a main bore 416 extending downwardly from the upper end404 as best seen in FIG. 23.

The body 402 includes several counter bores 418, 420, and 422 in itsupper end for receiving a ball valve assembly 424 therein. The ballvalve assembly 424 includes a ball valve element 426 received betweenupper and lower valve seats 428 and 430, respectively. The upper andlower seats 428 and 430 are received in first counter bore 418. A valveretainer element 432 is threadedly connected at 434 to the counter bore422. Valve retainer 432 includes a coupling 436 for connecting the sameto the fuel manifold line 40 seen in FIG. 1. It is noted that the line40 will typically include a shutoff valve (not shown) adjacent the inlet436 to the fill block.

The body 402 has a cross bore 438 which intersects counter bore 418. Avalve stem mechanism 440 is inserted through one side of the cross bore438 and engages the ball valve element 426 so as to rotate the same uponrotation of a valve handle 442.

As is apparent in viewing FIG. 23, the ball valve element is there shownin an open position wherein fluid may flow therethrough to and from thefill block bore 416. The handle 442 may be rotated 90° to move the valveelement to a closed position blocking the bore 416.

The cross bore 438 is plugged on the back side by plug 439.

A short distance below the cross bore 438 and at a right angle theretois a second cross bore 444 extending from left side 414 to right side410 and intersecting the main bore 416. The cross bore 444 has threadedends 446 and 448 which preferably are SAE threads.

On the backside 412 of body 402 there is seen another partial cross bore454 which has an enlarged threaded counter bore 456. The threadedcounter bore 456 provides a location for a threaded connection of themain fuel line (not shown) leading to the engine 38.

Moving on down the main bore 416, at an elevation a little over halfwaydown the length thereof, the main bore 416 is again intersected by twocross bores 450 and 452. Cross bore 450 runs from front side 408 to backside 412. It has a larger threaded opening 458 on the front side and asmaller threaded opening 460 on the backside. Again, all threadedopenings are SAE threads.

The cross bore 452 runs from left side 414 to right side 410 andincludes threaded ends 462 and 464.

As further described below, the front threaded connection 458 is afueling port. The other threaded connections 460, 462, and 464 providealternative connections for pressure gauges, pressure sensors and thelike.

The main bore 416 has a larger upper portion 466, and then narrows to asmaller diameter lower portion 468.

The lower portion 468 of main bore 416 is intersected by a defuelingvalve bore 470 which extends from left side 414 to right side 410.

A defueling valve 472 is received in bore 470 and includes a spool valveelement 474. A handle 476 is connected to spool valve element 474 forrotating the same between a defueling position and a venting positionwhich are further described below.

The lower reduced diameter portion 468 of main bore 416 continues allthe way to the lower end 406 where it is plugged by a plug 478.

Below the defueling valve bore 470, the lower main bore portion 468 isagain intersected by a partial cross bore 480 which has a threaded outerend connection 482. The cross bore 480 and threaded outer connection 482may also be referred to herein as a defueling port 480, 482.

As is seen in FIG. 21, the handle 476 is there shown in a defuelingposition wherein the defueling port 480, 482 is communicated with aportion of the main bore 416, 468 above spool valve element 474 so thatany fuel in the system can be relieved through the defueling port 482 ina manner further described below.

As viewed in FIG. 21, the handle 476 may be rotated 90° clockwise to avent position, wherein the spool valve element 474 closes the lowerportion 468 of main bore 416 so that fuel contained in the system cannotflow to the defueling port 480, 482. In this vent position, any fueltrapped below the spool element 474 is vented through a vent port 500 onback side 412 by means of a vent valve element 486 defined on the spoolvalve element 474.

As shown in FIG. 24, the spool valve element 474 includes first, secondand third O ring seals 488, 490 and 492 which define the defueling valveportion 494 of spool element 474 and the vent valve portion 486 of spoolelement 474.

The vent port 500 is connected to a drilled hole 502 (see FIG. 24) whichintersects a vertical drilled hole 484 which intersects and crossescross bore 472. Vertical hole 484 is plugged by plug 503.

When the spool valve 474 is in the defuel position illustrated in FIG.24, the vent valve portion 486 blocks drilled hole 484 and there is noflow to vent port 500.

When handle 476 is turned 90° to the vent position, the vertical hole484 is opened. Vertical hole 484 communicates with defueling port 480through a cross drilled hole 504 (see FIG. 23). Thus, when in the ventposition the small amount of gas trapped between defueling valve 472 anddefueling port 480 is vented to vent port 500.

In FIG. 20, there are somewhat schematically illustrated a fuelingreceptacle 496 which is connected to the threaded fueling port 458, anda defueling receptacle 498 which is connected to the defueling port 482.

The fueling receptacle 496 may for example be a Model CL5078 fast fillreceptacle manufactured by Sherex/OPW of Ohio.

The defueling receptacle 498 may for example be a Model SH2-63-643defueling receptacle available from Parker Fluid Connectors, 17325Euclid Ave., Cleveland, Ohio 44112.

Also seen on the front side 408 of block 402 are four shallow threadedblind bores 498, which provide a means for mounting the body 402 on thebus structure.

The operation of the fill block 400 is generally as follows.

In normal use of the bus 10, when the fuel system contains fuel andthere is no desire to add or withdraw fuel from the system, the shutoffvalve 424 is in its open position as illustrated in FIG. 23 so that fuelcan flow to the main fuel supply port 456. The defueling valve 472 isturned to its vent position to block any flow of fuel downward past thespool element 474.

When the bus becomes low on fuel, it is driven to a filling station, anda fuel supply line is connected to the fueling receptacle 496 by merelyplugging the fuel supply line (not shown) into the fueling receptacle496. As will be understood by those skilled in the art, the fuelingreceptacle 496 is a female portion which mates with the male portion onthe fuel line. The mating of the fuel line with the fueling receptacle496 opens a spring loaded valve element in the fueling receptacle 496,thus allowing CNG to flow from the source at the filling station inwardthrough the fill receptacle 496 and into the bore 416 and up through theopen ball valve element 424 to the manifold line 40 which carries thefuel to the fuel tanks where it is stored.

In the event that it is necessary to service some component of the fuelsystem, the fuel may be exhausted from the fuel lines or the fuel tanksby connecting the defueling receptacle 498 to a line leading to asatisfactory disposal receptacle (not shown) and then the defuelingvalve 472 is moved to its defueling position to allow the pressurizedCNG in the fuel line or manifold line 40 or the fuel tanks to flow outof the defueling receptacle 498 thus draining the desired portion of thefuel system which is open to the fill block.

Thus, it is seen that the apparatus of the present invention readilyachieves the ends and advantages mentioned as well as those inherenttherein. While certain preferred embodiments of the invention have beenillustrated and described for purposes of the present disclosure,numerous changes in the arrangement and construction of parts may bemade by those skilled in the art, which changes are encompassed withinthe scope and spirit of the present invention as defined by the appendedclaims.

What is claim is:
 1. A fill block for a CNG fuel system for a vehicle,comprising: an integral one piece body having first and second endsdefining a length therebetween, the body having a main bore definedtherein; a ball valve received in the body and having a handle extendingfrom the body, the ball valve being movable between open and closedpositions wherein the main bore is open and closed, respectively; afueling port defined in the body and communicated with the main bore; adefueling port defined in the body and communicated with the main bore;a fueling receptacle connected to the fueling port; a defuelingreceptacle connected to the defueling port; and a defueling valve forselectively communicating the defueling port with the main bore andisolating the defueling port from the main bore.
 2. The fill block ofclaim 1, further comprising: a vent port; and wherein the defuelingvalve is constructed to connect the vent port to the defueling port whenthe defueling valve isolates the defueling port from the main bore. 3.The fill block of claim 1, further comprising: first and second gaugeconnection ports on opposite sides of the body so that a pressure gaugecan be connected to either side of the body.
 4. The fill block of claim3, wherein the gauge connection ports have SAE threads.